Harvesting apparatus for tall-growing crops

ABSTRACT

The harvester provides a self-propelled or towed base ( 2 ) on which a telescoping tower ( 3 ) is mounted on a gimbal ( 7 ), allowing angular flexibility of the tower relative to the base. The tower resists swaying movement by the stabilizing effects of hydraulic cylinders ( 34 ) that are connected to electrically-operated hydraulic control valves, e.g. servo valves, controlled by a programmable logic controller or the like, which receives input from two inclinometers ( 5 ). An extendable multi-jointed boom ( 8 ) is mounted at or near the upper end of the tower. Mounted at the distal end of the boom is a cut fruit holding basket ( 11 ) and a funnel ( 12 ) with a chute ( 13 ), mounted to a common platform ( 4 ) that pivots to provide access to all sides of a tree. Collected fruit may be discharged periodically into a collection bin, for example when the platform is at least partially lowered to move the base and tower from location to location.

TECHNICAL FIELD

This invention relates to harvesting equipment for tall-growing crops,and in particular to a machine (harvester) which can efficientlyfacilitate harvesting of palm fruit, for example.

Throughout the remainder of this description, all references will be topalms, but it should be clearly understood that the invention could beuseful in any other application requiring rapid and efficient access tosuccessive tall trees or plants.

Palms for palm oil production are typically grown in plantations within20 degrees of the equator in areas of high rainfall. In addition tobeing the most productive edible oil crop (10 times the next mostproductive), it is one of the last significant food crops that todaygenerally is not mechanically harvested. It is estimated that twobillion ringit (about 500M US$) worth of palm oil is lost due to theinefficient harvesting practices currently used. Traditional manualharvesting of palm oil is extremely inefficient because of the heightsto which the palm trees grow, making access to the fruit difficult andawkward, and resulting in significant waste because of unharvested fruitleft behind.

The present invention will maximize the quantity of palm fruitharvested, and simplify crop maintenance.

BACKGROUND ART

Traditionally, there are several steps involved in harvesting palmfruit. For short young palms (1-3.5 m tall), a sharp flat blade attachedto the end of a steel water pipe (making a chisel with a 6-foot handleand a blade that is 6 inches wide at the end) is used to cut the fruit.To cut a fresh fruit bunch (hereinafter referred to as “FFB”), a cutteraccelerates the blade into the FFB stalk with a underhanded upwardmotion. The weight of the water pipe provides enough inertia and storedenergy to sever the stalk.

For older, taller palms (3.5-15 m tall), a sharp blade (roughly the sizeand shape of a hand scythe blade) attached to the end of a long (13+m)adjustable pole is used. The cutter carries the pole upright. It isphysically taxing to raise and lower the pole because of its length.When the cutter identifies a ripe fruit, he maneuvers the blade aroundthe top of the FFB stalk and cuts it with a vigorous downward pull onthe pole. The fruit falls to the ground and, depending on the height, anumber of fruitlets (loose fruit) will separate from the FFB uponimpact. Loose fruit is by weight the most valuable part of the harvest.

An experienced cutter can harvest 50 to 133 bunches per day depending onheight, terrain, season and how well the palms are pruned.

Once the fruit is cut, the next step involves the in-field collection,which is achieved by a second laborer, manually collecting and carryingthe FFB to a haul road in a sling or on his shoulder. Loose fruit isgenerally collected with the use of a scoop (typically cut out of aplastic jug) and a bucket or fertilizer bag, or it is collected with awheelbarrow, making the collector's work easier (but not significantlyeconomical in the case of tall palms, as the rate of harvest is set bythe cutter). The fruit is then carried to the haul road and left at aFFB pile.

The final stage involves moving the fruit from the haul road by atractor (typically around 60 HP) pulling a trailer (typically 6 to 7tonnes) along with several chargers (laborers equipped with spears orspikes) who travel down the roads stopping to pick up fruit at row ends,spearing the fruit with 3-foot spikes and throwing them over the side ofthe wagon. When the wagon is full, the tractor pulls it to a chute areawhere the fruit is dumped, much like the action of a dump truck. Trucksfrom the mill back under a chute (built on a hill with fruit dumped ontop of hill) and a tractor equipped with a front-end loader pushes fruitdown the chute onto the truck. This is the least efficient mechanism, asfruit is handled three times (generally causing damage each time). Also,the rate of collection is not well matched to the rate of cutting. Thetall palm cutter is slow, so the collector's work rate is also slow andhe is under-utilized, whereas the short palm collector is probablyoverworked.

There are presently several options to “mechanize” the collection ofpalm fruit. A “mechanical buffalo”, which is a simple 3-wheel carrierwith a 400 kg payload and a dump bin, has been used in the collection ofthe fruit once it has been cut, as described above. To collect fruit,one or two chargers travel down the travel rows after the fruit is cut,using spikes to spear FFB and load into mechanical buffalo dump bin.When full, the load is dumped at the haul road and the rest of theevacuation process to the mill is as above. If loose fruit is collected,it is a separate operation as the FFB collection process is too fast forloose fruit collection. This process has proven to be more efficientthan hand carrying by reducing the direct labor content and substitutingcapital.

Another option for collecting fruit is the use of a mini tractor/grabberwhich is a mini-tractor (25 hp) equipped with a hydraulic grabber, (adevice like a small boom crane mounted on the back of the tractor)towing a scissor lift trailer. The operator drives down the palm rowsusing the grapple to pick up fruit in front of him, and deposits it inthe trailer behind him. As with the mechanical buffalo, a separateoperation is required to retrieve the loose fruit. When the trailer isfull it is driven to a large over-the-road trailer (or a large bin thatis power loaded onto a trailer like a North American refuse bin), thatis placed in the field at a convenient location.

Commercially available aerial lift devices have been experimented withbut have not been adopted by the palm oil industry. The chief drawbackof these devices is that they cannot position an operator fast enough tobe economically practical. Specific classes of machines and theirproblems are discussed below:

-   -   Articulating Boom Lifts: These devices elevate by means of long        arms with rotary joints that straighten out to move an operator        into the air and are exemplified by the bucket trucks one sees        doing powerline work. These devices cannot be operated quickly        nor can they travel over the ground quickly with an operator in        them. They are basically a mass at the end of cantilevered beam        and would result in unacceptable jostling of the cutter when        moving between trees.    -   Telescoping Boom Lifts: These devices generally have heavy booms        and require significant counterweight and/or hydraulic        outriggers, making them prohibitively heavy and slow to operate.        In addition they cannot access the back side of a palm and so        must be maneuvered on the ground to a place where the fruit is        accessible.    -   Scissors Platforms: Platforms that are elevated by a scissors        mechanism are heavy and slow to raise, and cannot be positioned        easily, nor practically.

Drawbacks of the prior art in generally include the following:

-   -   Lack of Trained Workers (Tall Palm). Harvesting of tall palm        (12M+) is a difficult skill to acquire. Typically, cutters grow        up on the plantation, and thus train over a number of years.        Harvesting palm is physically demanding, which is exacerbated by        the heat and humidity.    -   Crop Loss (Tall Palm). The height to which the palms grow, and        the restricted visibility due to poor thinning, make it        difficult for a cutter to identify ripe fruit, so it is often        missed. Palms are not of uniform height so it is often necessary        to adjust the length of the harvesting pole. Because the workers        are paid on a piecework basis, the energy and time required to        harvest the occasional tall or short palm is not worth the        money, and these fruits are bypassed in favor of easier fruit.        Furthermore, fruitlets which fall off the FFB when it hits the        ground all are not all recovered.    -   Fruit Damage. The more the fruit is handled, the more it is        damaged. When the FFB falls from the tree the fruit is bruised,        which starts a chemical reaction that reduces the value of the        crop. The longer it takes to be processed, the greater the        decline in value. At every handling this situation is        aggravated. The traditional method handles the fruit five times        (drop from tree, drop at road, load into wagon, drop at chute,        load into truck), and even the most advanced methods involve at        least three handlings.

Access in Wet Weather. Existing harvest collection methods depend onvehicle systems that do not have a high degree of mobility over softground. This makes harvesting problematic during monsoon season, andgenerally over any ground that is marshy.

To be commercially viable, a machine ideally should achieve most or allof the following objectives, on average at least once a minute:

-   -   1. Travel 27 m between trees    -   2. Move the cutter from his position while traveling to a fruit        that is 15 m+high.    -   3. Position the cutter directly below the fruit to be harvested,        anywhere around the circumference of the tree    -   4. Allow the cutter to cut the fruit easily    -   5. Convey the cut fruit to a bin (dump box)    -   6. Return the cutter to the travel position and begin moving to        the next tree.

DISCLOSURE OF INVENTION

To address the above drawbacks of the prior art, the invention providesan integrated harvesting machine having a self-propelled, aerial liftdevice with an elevating dump box that moves from the palm to a roadsidecontainer for transport to the mill.

The invention includes a towed or self-propelled vehicle with avertically telescoping tower that has a man-carrying platform attachedto the end of a multi-jointed boom. The configuration enablespositioning a cutter in close proximity to the fruit for effectiveharvesting. Attached to the platform is a flexible, extendable funnelarrangement that terminates above an elevating dump box.

The invention allows a trained operator to come into close proximity tothe crown of the palm and to quickly identify the fruit to be cut andmaneuver a tool to a position to cut that fruit so that it falls into acollection means, which can be periodically discharged into a dump box.Then dump box, when full, is transported to and dumped into a container(truck) that can be moved to the mill quickly and efficiently over avariety of ground conditions with a minimum of damage.

Use of the invention will very significantly reduce the directharvesting labor requirements. Furthermore, since the level of manualdexterity required to operate the machine is modest, operators can betrained in less time than for hand cutting. More significantly, thephysical labor is significantly reduced, making the job attractive to alarger number of people. Elimination of labor issues will minimize croplosses due to scarcity of labor. Other advantages of this inventioninclude making identification and harvesting significantly easier, thusavoiding missed fruits. The height of the fruit is not an issue for thecutter because of the ease with which one can move up and down.

Elimination of hand carrying reduces the density of haul roads requiredand increases the amount of land available for cultivation. Circlesunder the trees that were needed to retrieve loose fruit, and had to bemaintained with traditional harvesting, are no longer required sincethere is no loose fruit to retrieve. The invention also will facilitatethinning of palms at the time of harvest, with minimum incrementaleffort. Harvesting can be accomplished in wet weather because theoff-road capabilities of the vehicle will greatly surpass that oftractors towing trailers, allowing evacuation even during monsoonseason.

BRIEF DESCRIPTION OF DRAWINGS

The invention will now be described in greater detail, with reference tothe accompanying drawings of preferred and alternative embodiments asexamples, listed as follows:

FIG. 1 is a perspective overview of the harvester, showing the towerextended and the platform positioned at a palm for harvesting;

FIG. 2 is a view of the harvester with its tower retracted;

FIG. 3 is a view of the extended boom and the platform showing theperson-carrying basket and the funnel;

FIG. 4 is a view of the extended boom and the platform showing thebasket and the funnel;

FIG. 5 is a view of the extended boom and the platform showing thebasket and the funnel;

FIG. 6 is a view of the extended boom and the platform showing thebasket and the funnel;

FIG. 7 is a side view of the carrier showing the extended tower and theextended boom, with the funnel emptying into the dump box;

FIG. 8 is a side view of the carrier showing elevation of the dump box;

FIG. 9 is a front view of the carrier with the extended tower and boom;

FIG. 10 is a top view of the carrier, showing only the frame structureand the base for the tower with mounted tower;

FIG. 11 is a top view of the platform held by the boom, adjacent a palmtree;

FIG. 12 is a top view of the platform held by the boom, adjacent a palmtree;

FIG. 13 is a top view of the platform held by the boom, adjacent a palmtree;

FIG. 14 is a top view of the platform held by the boom, adjacent a palmtree;

FIG. 15A is an end view of the boom holding and pivot structure;

FIG. 15B is a side view of the boom holding and pivot structure;

FIG. 16 is a top view of the hydraulic cylinders mounted to thetelescoping tower and the base of the carrier;

FIG. 17 is a side view of the gimbal-mounted telescoping tower;

FIG. 18 is a partially sectioned side view of the tower, showing apulley system for raising and lowering the tower and the support wheelsof the tower segments;

FIG. 19 is a partially sectioned top view of the boom, showing thesupport wheels of the tower segments;

FIG. 20 is a view of the tower in position for the funnel emptying intothe dump box;

FIG. 21 is a view of the elevated dump box during discharge from thedump box to a transport vehicle;

FIG. 22 is a view of the boom and the platform moving about thecircumference of the palm tree; and

FIG. 23 is a view of the boom and the platform moving about thecircumference of the palm tree.

BEST MODE FOR CARRYING OUT THE INVENTION

The invention includes a vehicle or carrier 1, either self-propelled ortowed, providing a base 2 on which a telescoping tower 3 (vertical boom)is mounted on a gimbal 7, allowing angular flexibility of the towerrelative to the base. The tower 3 resists swaying movement by thestabilizing effects of hydraulic cylinders 34 that are connected toelectrically-operated hydraulic control valves, e.g. servo valves (notshown). A programmable logic controller (PLC) or a microprocessor whichreceives input from two inclinometers 5 controls these valves (see FIG.16). This mechanism allows the tower to remain vertical while thevehicle is moving over sloped or undulating ground. This feature of theinvention is important as it allows the vehicle to move quickly betweenthe trees while maintaining the comfort and safety of the cutter who ispositioned on a platform 4 at the top of the tower, and maintains theoverall stability of the vehicle.

Other means of maintaining a level platform or base when moving overuneven or inclined terrain are known, and could be readily adapted tothe present invention. The invention is not necessarily limited to thespecific leveling means just described.

The tower 3 preferably is a closed-section box structure that is stiffcompared to open-sections characteristic of many other telescopingmechanisms, thus reducing the whip the operator might otherwise feelwhile moving at such a height. It could also be tubular, i.e. circularin cross-section. The tower is mounted to one side of the center of thecarrier 1, to act as a counterweight to offset the overturning momentthat would be caused by the outward movement of the operator whileharvesting.

An extendable multi-jointed boom 8 (horizontal boom) is mounted at ornear the upper end of the tower 3. The boom extension could be anylinear actuating device, for example in this case a fluid power cylinder9. The extension of the boom is continually monitored by a linearpositioning feedback device. The boom 8 is slidingly held in a boomholder 22 and the cylinder 9 is held in a cylinder holder 23, which isfixed to the boom holder. The cylinder has a piston rod 24, which isfixed to the boom 8 at a piston rod attachment 25.

The boom rotating device could be any device or linkage that creates anorbital motion, in this case a fluid power rotary actuator 10. Therotary position of the boom is continuously monitored by a rotaryposition feedback device.

Mounted at the distal end of the boom is a cut fruit holding basket 11and a funnel 12 with a chute 13, mounted to a common platform 4 thatpivots. The platform rotating device could be any device or linkage thatcreates orbital motion, in this case, a fluid power rotary actuator 15.The rotary position of the platform can be continuously monitored by arotary position feedback device. Also mounted on the platform 4 is acutting operator holding structure 6, with a protective guardrail. Thebasket 11 has vertically indented portion 11′ arranged on opposite endsof the basket, to allow fitting one indentation around a part of a trunkof a palm tree 14.

The pivot point of the fluid power rotary actuator 15 is arranged atsome distance from the center of the funnel 12 so that a combination ofthe above-mentioned positioning feedback devices, and a suitablealgorithm to control the power of the actuators, will enable the funnelto be moved in a circular path around the palm 14, permitting 360°access to the palm fruit during a single set-up, using a single controldevice. Otherwise three controls for the rotary actuators 10 and 15 andboom extension 24 would have to be manipulated in a controlled fashion,which would be slow and which would require too much skill to beeconomical.

FIG. 1 shows the overall machine, having a telescoping vertical tower 3extending upwardly from the vehicle 1, offset away from the working sidefor built-in counterbalancing. The tower 3 has a plurality oftelescoping members. Shown are a first member 3′ and a second member 3″.Preferably two outriggers 17 are also provided, for lateral stability,preferably mounted on each side of a forward portion of the carriervehicle 1. They can be raised and lowered quickly when moving fromlocation to location. Extending horizontally outwardly from the top ofthe tower is the boom 8 with its platform 4 and basket 11 at a distalend for the worker, and a funnel 12 connected to a chute 13 which can bedischarged periodically to a collection bin 18. The funnel/chuteassembly has a trap door 19 or the like, which the operator can actuateto dump the collected fruit while traveling between palms. For betterstability, the platform typically will be lowered to about half of itsmaximum height when traveling between palms, and will be positioned overthe dump box (collection bin) 18, so that is when the operator wouldactuate the trap door arrangement. The collection bin preferably ismounted on a scissor lift 20 as shown in FIG. 8, so that it can beraised and lowered as desired, for example for dumping as in FIG. 8 orFIG. 21. In FIG. 21, a transport truck 35 is shown, as an example oftransport vehicles used. Other examples are railway cars andboats/ships/barges.

Preferably, on command from the operator, the funnel 12 willautomatically locate at a fixed height and position above the bin 18,for gravity discharge upon release of the trap door 19, which may alsobe automatic. Once automatically located, the operator preferably canoverride the automatic position and relocate for discharge elsewhere ifdesired. Preferably, the PLC or computer is programmed so that thefunnel can be returned automatically (if selected by the operator) toits previous palm head location directly via the shortest route.

Preferably, the palm head starting position is predetermined asvertically above the front right vehicle tire 21 which is adjacent tothe palm, and the default height is preset according to the field beingworked.

As can be seen from FIGS. 3 and 4, the platform 4 and funnel 12 andchute 13 assembly swings around at the end of the boom, to allowopposite sides of the palm to be harvested. The pivot point is arrangedat some distance from the center of the funnel so that a combination ofthe four degrees of freedom of motion (up-down, in-out, left-right, andpivot) will allow the worker and funnel to be positioned at any desiredlocation around the circumference of the palm.

Preferably, the machine's controls will incorporate a computer or PLCprogrammed to coordinate the motion of the platform to create a circularpath around the tree, based on input from a single control like arheostat rather than manually-coordinated control of three actuatingdevices that would normally be required to produce the same motion. Theimportance of this is that manually controlling this action is verydifficult and thus slow, requiring a long training curve, whereasautomatic operation with one control can be fast and makes the operationmore economical.

In general, the worker on the platform 4 will have some controls, andthe vehicle driver will have some controls. If desired, the controlscould be entirely duplicated, so that either person could control anyfunction.

A preferred mechanism for raising and lowering the tower 3, with itsfirst member 3′ and second member 3″, is shown in FIGS. 18 and 19. Thetower first support wheels 32 and the first segment has second supportwheels 33, to guide the first segment during its movement relative thetower. The first segment 3′ further has third support wheels 30 and thesecond segment 3″ has fourth support wheels 31, to guide the secondsegment during its movement relative the first segment. The raising andlowering movement is provided by a rope 26, which runs over pulleys 29fixedly arranged inside the first segment and the second segment. Therope is coiled and uncoiled onto a drum 27 by a remotely operated andreversible winding motor 28. Other propulsion systems may be used toprovide the movement for the first and second segments, for instancehydraulic cylinders preferably located inside the tower and the firstand second segments.

INDUSTRIAL APPLICABILITY

The invention provides for more effective harvesting of tall-growingcrops.

1. A harvesting machine, characterized by: a transportable base (2),having a gimbal-mounted telescoping tower (3) extendable generallyvertically upwardly therefrom; means (5, 34) for maintaining said towerin a generally vertical orientation regardless of the orientation ofsaid base; an extendable boom (8) mounted at an upper portion of saidtower, extendable generally horizontally away from said tower; a workplatform (4) mounted at a distal end of said boom; and collection means(11) on said work platform for receiving harvested crop.
 2. A machine asrecited in claim 1, wherein said work platform is pivotally mounted, forpivoting about a generally vertical axis.
 3. A machine as recited inclaim 1, wherein said means for maintaining said tower in a generallyvertical orientation comprises actuators (34) arranged between said baseand said tower, inclinometers (5) on either or both of said base andsaid tower, and automatic control means for actuating said actuators inresponse to inputs from said inclinometers.
 4. A machine as recited inclaim 1, wherein said tower is mounted on a side of the base oppositethe side from which the boom extends, for inherent counterbalancing. 5.A machine as recited in claim 1, wherein said collection means comprisesa basket (11) having a funnel (12) connected to a chute (13), andwherein said base carries a collection bin (18) into which said chutemay be periodically discharged.
 6. A machine as recited in claim 1,wherein said base is carried by a self-propelled vehicle (1).
 7. Amethod of harvesting a tall-growing crop using a harvesting machine asin claim 1, said method characterized by operating said harvestingmachine to elevate said platform to the general height of the product tobe harvested, manually collecting said product and depositing it in saidcollection means, lowering said platform at least partially whensufficient product has been collected at one location, to a height whereproduct may be discharged from said collection means, moving said baseto another location, and again elevating said platform to repeat thepreceding steps.
 8. A method as recited in claim 7, using a harvestingmachine as in claim 5, wherein said product is discharged from saidbasket via said funnel and chute, into a collection bin.